Packaging Machine and Method for Paperboard Cartons

ABSTRACT

A packaging system and device for paperboard cartons having closure flaps which extend across and seal the carton opening when filled with articles. The flaps, which are prone to distortion, are treated with a minor amount of water which reverses the distortion and allows the articles to be successfully inserted through the opening and into the carton.

FIELD OF THE INVENTION

The present invention relates to packaging of primary articles such asbottles into secondary containers such as cartons. It is particularlyconcerned with a method and apparatus for ensuring that preformedcollapsed paperboard cartons, termed “flats”, which are generallyerected or set up to form cartons in a bottling facility and which arethen transferred to the next workstation in the packaging process are ina fully open condition.

BACKGROUND OF THE INVENTION

Article packaging machines are well known and readily commerciallyavailable. Such machines are widely used, for example, in the beverageindustry by brewers, soft drink manufacturers and the like to accomplishthe packing of primary containers such as bottles, cans, etc. ofbeverages into secondary containers, namely cartons, made of corrugatedcardboard, paperboard or a similar strong paper product. The erectedcartons are generally produced in situ in the packaging facility fromblanks which, typically, have a plurality of co-planer walls, panels andflaps that are separated by fold lines. Such flats are delivered to theuser in that form because they are easy, convenient and less costly toship and store in the packaging facility. The user in turn sets them upinto the required three-dimensional, usually rectangular, configurationwith an opening to receive a complement of primary containers. This stepis usually effected by means of automatic devices following theirdelivery from storage. Examples of such machines are disclosed in U.S.Pat. Nos. 3,956,976; 5,411,464; 4,571,916 and 6,050,063. Following beingset up, they are subject to further processes, for example, being filledwith articles such as bottles. Various types of devices are employed forfilling the erected containers. Many of these involve “top loading”,i.e. the carton contents are dropped through the open top of thecontainer after the container bottom has been formed. The droppingmethod can be unreliable and cause problems because many of the primaryarticles can fall out of position, especially if the path into thecarton is in any way hindered. To be effective, the carton has to bepacked carefully and with precision especially when, as in the brewingindustry, the length and breadth dimensions of the carton, and thereforeof the opening through which the primary articles must pass, are onlymarginally larger than that of the block or “unit” of bottles beinginserted, since the cartons are designed to prevent movement of enclosedbottles. Any obstacle to the insertion of the articles is therefore asignificant problem.

In addition, in erecting the carton, the closure top flaps, whichcomprise the top of the carton following filling and sealing, mustinitially be spread outwardly, i.e. away from the open top so that theydo not interfere with the insertion of the articles into the erectedempty carton. It will be appreciated that the complement of thearticles, e.g. bottles, say 6 or 12 being top loaded into the opencarton constitute a rectangular “unit” of having a configuration of say2×3; 2×6 or 3×4, bottles. Any obstruction to the insertion of theassembled “unit” into the proposed carton results in an inability toinsert the unit and disruption of the high speed filling line which thenhas to be shut down with severe economic implications. Possible problemswith the flaps is usually effected using cams or similar tools—refer forexample to U.S. Pat. No. 3,956,976. However, there are still problems,many of which relate to the characteristics material, such aspaperboard, from which the cartons are made. In particular, at certaintimes of the year, the carton material can loose moisture and, when thecarton has been set up, the top flaps have a tendency to “bow” out orbuckle out of shape and thereby partially extend across and obstruct theopening into the empty carton. This interferes with the loading of thecarton, the serious consequences of which are detailed above.

It is an object of the present invention to provide a device and amethod to ensure that the closure flaps of an erected carton do notobstruct the carton opening thereby preventing clear insertion ofarticles into the carton.

STATEMENT OF INVENTION

It has been found that providing moisture to the flaps of an erectedcarton prior to it reaching the next processing station in a packingline corrected any tendency of the flap to distort, for example, bow orbuckle, and thereby hinder or prevent the next step or stage in thepacking process from being successfully effected. In particular, acarton closure flap which, because of distortion due to dryness, bucklesand overlaps the opening in the carton thereby hindering or totallypreventing entry of the complement of articles to be packed into thecarton, when moistured, quickly adopts its original and generallyplanner condition lying outside the area of the carton opening to allowsaid articles to be inserted into the carton without hindrance. Thepresent invention can be used to advantage in the packing of paperboardcartons, such as end loaders but especially of the top loading typewhere obstruction of the carton opening by distorted closure flaps canbe a problem.

It should be noted that the carton flaps should be treated withsufficient moisture to correct the buckling caused by dryness butinsufficient to over wet the carton. If the carton material remains wetfor a prolonged period, which might result from over wetting, there maybe a tendency for mold to form, a highly undesirable event. Also,excessive wetness could result in the wet carton material tearing. Theactual amount of moisture required is readily determined by simpleexperiment; The take up or absorption of the moisture by the boardmaterial, especially paperboard material is quite rapid and so is thecorrection of the way or distortion, i.e. its reversal to its originalposition of the board material.

Obviously, the present invention has application in any situation wheregenerally secondary, but also primary, cartons used in a packingoperation encounters the same drying out problem as outlined above.Hence, end and side loading carton filling operations; the packaging ofother food and non-food articles; and the like can all benefit by use ofthe present invention. The moisture can be applied in a mist or sprayusing known spray heads.

In one embodiment therefore, the present invention provides a method oftreating a paperboard container at least part of which is distorted bydehydration which adversely affects its use for its intended purpose,comprising applying to the distorted portion of said carton moisturewhich when absorbed, is sufficient to co-interact said distortion andrender same ineffectual.

A special application of the present invention is when the carton is inan erected condition having sealing flaps distorted through dehydrationso as to overlie the opening through which the product is inserted intothe carton. Said flaps are treated with moisture, which upon absorptionby the flaps counteracts said distortion thereby ensuring access to thecarton for the products.

The cartons to be filled may be of the type having a pre-glued bottomflaps and a locking system which engages when the collapsed carton isfully open or erected thereby holding the carton open so that articlescan be inserted past spread outwardly extending flaps. The carton isthen transported to an article loading machine which introduces thearticles such as bottles, into the open carton and, subsequently, causesrotation of said flaps to overlie the articles in an abuttingrelationship where they are secured together by, for example, hot meltadhesive to seal the carton.

According to a further embodiment, the present invention there isprovided a form, fill and seal packaging machine adapted to receive acarton flat having sealing flaps susceptible to warping when dehydrated,erect the carton flat into an open carton, fill and seal the opencarton, the machine comprising a frame means for erecting the cartonblank into a carton having an opening, closurable by said sealing flaps,for the insertion of articles; means for moistening the sealing flaps tocounteract or prevent any warping of said flaps which would hinderinsertion of said articles into said carton; means for filling saidcarton with a complement of articles; means to manipulate said flaps tooverlie said articles; and means to secure said flats together to sealsaid carton.

According to yet a further embodiment of the present invention, there isprovided a method for packing articles into a carton, said processcomprising manipulating a carton flat having flaps adapted to seal anopening into the carton into an erected open condition, moisturizing anywarped closure flaps to negate said warp during transport of said cartonto a packing station where it is filled by inserting a complement ofarticles through said opening into said container, manipulating saidflaps so that they overlie the articles in the carton and securing theflaps together to seal the carton.

DRAWINGS

The present invention will be described, but not limited by, referenceto the accompanying drawings in which:

FIGS. 1 to 4 show stages of set up of a top loading carton flat—shown inFIG. 1—to the erected open carton—shown in FIG. 4.

FIG. 5 is an angled perspective of an erected carton with its top sideclosure flaps distorted.

FIG. 6 is a top plan view of the carton of FIG. 5.

FIG. 7 is a schematic drawing showing of a packaging line showing theroute taken by a carton during a packaging operation.

FIG. 8 is an angled perspective from above and a side of a hydratingstation according to the present invention.

FIG. 9 is an angled perspective from above and a side of part of theconveyor system which transports erected cartons to a packer.

In the drawings, a top loading carton, generally designated 27 has sidewalls 1 and 5; end walls 2 and 6; top side closure flaps 3 and 4 and topend closure flaps 7 and 8. FIG. 4 shows how the top closure panels 3, 4,7 and 8 are generally oriented in the open erected carton 27. FIG. 3shows how the bottom wall, generally designated 9, is formed fromsections 10, 22, 12 and 13.

Side wall 1 is foldably interconnected at 16 with end wall 2 and sidewall 5 is foldably interconnected with end wall 6 at 17. The bottom wall9 is a composite of the numbered bottom wall sections 10, 11, 12 and 13hinged to the lower edges of the side and end walls. The bottom wallsections include section 10 foldably connected to the bottom edge ofside wall 5; section 11 foldably joined to the bottom edge of end wall6; section 12 foldably joined to the bottom edge of side wall 1 andsection 13 foldably connected to the bottom edge of end wall 2.

A securing flap 11 is foldably joined to the bottom edge of end wall 6and is secured in place in contacting relation to section 12 and theseoverlapping panels include coinciding diagonal fold lines. A furthersecuring flap 13 is foldably joined to the bottom edge of end wall 2 andis secured in place contacting relation to section 12 and theseoverlapping sections include coinciding diagonal fold lines. When acollapsed carton 26 is pressed inwardly at joints J it is converted fromthe collapsed condition shown in FIG. 1 to where the carton walls form arectangle in cross-section (refer FIG. 4); the diagonal fold lines arepositioned in general alignment with each other and notches 14 and 15formed on the edges of sections 10 and 12 become interlocked to securethe carton 27 in its erected condition shown in FIG. 4. It may be notedthat the sealing flaps 3, 4, 7 and 8 are spread outwardly so that theydo not interfere with the insertion of product into the erected orexpanded carton. As indicated in the sequence shown in FIG. 1 to FIG. 4,the flat or collapsed carton 26 of FIG. 1 is first converted to theposition shown in FIG. 2 due to movement toward the right of side wall 1whilst maintaining side wall 5 in its original position. This relativemovement continues until the carton 27 attains the position shown inFIG. 4. Of special note is the planer character and orientation of topclosure flaps 3, 4, 7 and 8 each of which in the flat carton wasoriginally in a plane including its associated side or end wall to whichthey are attached via hinge lines 18 and 19 each flap being angled outof the plane including its associated side wall and away from cartonopening 20. Consequently, the opening 20 of carton 27 is not obstructedby any of the top closure flaps 3, 4, 7 or 8. This is the situationrequired for successful filling and efficient operation of the packagingline. Erection of the carton 10 can be effected using a number ofcommercially unavailable machines such as that described for example inU.S. Pat. No. 5,411,464 mentioned above.

The plane characteristic or condition of the top flaps are shown in FIG.4 is the ideal one. The exaggerated condition of the top flaps as shownin FIGS. 5 and 6 is, however, not an unusual one especially in drierseasons such as during a Canadian winter. As can be seen, the largerside top closure flaps 3 and 4 are distorted or buckled bow inwardlytaking up a position overlying part of the opening 20 of container 27.This is usually attributable to the flaps becoming dehydrated to somedegree during storage. In any event, attempting to drop load arectangular “unit” comprising a full complement of six (in a 2×3configuration) beer bottles into the container shown in FIG. 6 would notbe successful. The unit jams against the flaps 3 and/or 4 casing one ormore bottles to fall over, etc.

FIG. 7 illustrates in schematic form, the overall inventive packingprocess. Flats from storage arrive via conveyor 21 at the cartonerection or set-up station 22. Following being set up they aretransported to, and through, a moisturizing or hydrating station 23 andon to the bottle packer 24. Following being packed with a fullcomplement of filled bottles of beer and sealed, the package is furthertransported to a palletizer 25. Finally, the pallets loaded with theretail beer packs are moved to storage.

Turning to FIG. 8, this illustrates a hydrating station, generallydesignated 23, of the present invention. The station 23 comprises incombination a carton support, in this case a section 31 of a conveyor32, and a hydration system, generally designated 33 comprising a waterdelivery tube 34 which also carries and supports a moisturizing head 35.Head 35 has two nozzles 36 each angled laterally to the direction oftravel of the carton 27 and arranged to direct a fine water mist orspray in a vertical line sufficient to apply moisture to substantiallyall of the inside surface 30 of each carton side top flap 3 and 4 asthey are transported through the station. Tube 34 is secured to guiderails 38 and 39 via clamps 40 and is connected to a source (not shown)of pressurized water.

It should be noted that top end flaps 7 and 8 are note shown in full inFIGS. 8 and 9. These flaps are relatively small in this carton and hencedistortion is not a significant problem and, as a practical matter, canusually be ignored. If necessary, however, those flaps could also besimilarly moisturized by providing additional spray nozzles 36 orseparate additional spray heads 35.

Following being treated, carton 27 continues along conveyor 32 andduring this time, treated top side flaps 3 and 4 absorb the appliedmoisture and regain their original and desired planer characteristic asshown in FIG. 9. Note that the total open area or opening 20 of thecarton top is then unobstructed by the top flaps 3 and 4. This occursquite quickly and hence the distance between the hydrating section 31and the packer 24 can be relatively short and not take up much floorspace.

To summarize the operation of the device of the present invention, thecarton 100 having distorted top closure flaps 3 and 4 is, followinghaving been set up at the erector 22, is transported via conveyor 21through hydrating station 23 where substantially all of the interiorsurface 30 of each of top side closure flaps 3 and 4 are subjected to afine spray or mist of water (indicated by the dotted lines) in FIG. 8.The carton 27 then exits the hydrating station 23 and is transported totop loading bottle packer 25. During the time of transport between thosestations, the moisture is taken up by the top side closure flaps 3 and 4which regain their original planar condition prior to reaching packer24. Consequently, any tendency of the flaps 3 and 4 to obstruct cartonopening 20 is removed and the carton 100 is successfully packed andsealed at the packing station. As a practical matter, all cartons 100travelling on the conveyor are treated with the spray to ensure allthose dehydrated and requiring treatment do receive it.

It may be noted that this treatment does not adversely affect the usualcarton sealing method, that is, the use of hot melt adhesives since thehot glue is not affected by moisture.

The present invention can, of course, be used to advantage in anysituation where a carton opening is restricted or obstructed by overlydry closure flaps. Consequently, if could be used in association withside or end-loading operations as well as the packaging of other food ornon-food articles, yogurt containers or plastic utensils.

1) A method for treating a carton having a flap member distorted bydehydration comprising applying sufficient moisture to said member tocause re-hydration thereof. 2) A method for treating an erected cartonwhich has at least one sealing flap member distorted through dehydratingthereby obstructing an opening in said carton, said method comprisingtreating said flap with sufficient moisture to re-hydrate same andnegate said distraction. 3) A method for packing articles into a carton,said process comprising manipulating a carton flat having flaps adaptedto seal an opening into the carton wherein an erected open conditionmoisturizing any warped closure flaps to negate said warp duringtransport of said carton to a packing station where it is filled byinserting a complement of articles through said opening into saidcontainer, manipulating said flaps so that they overlie the articles inthe carton and securing the flaps together to seal the carton. 4) Apackaging machine adapted to receive a carton flat having sealing flapssusceptible to warping when dehydrated, erect the carton flat into anopen carton, fill and seal the open carton, the machine comprising ameans for erecting the carton blank into a carton having an opening,closurable by said sealing flaps for the insertion of articles; meansfor moistening the sealing flaps to counteract or prevent any warping ofsaid flaps which would hinder insertion of said articles into saidcarton; means for filling said carton with a complement of articles;means to manipulate said flaps to overlie said articles; and means tosecure said flats together to seal said carton.